Polyurethane compositions, polyurethane foams having reduced odor prepared with same and preparation methods thereof

Abstract

A polyurethane composition, comprising (A) an isocyanate compound; (B) a polyol compound; and (C) an amine-based catalyst system comprising (C1) at least one amine-based catalyst and (C2) at least one deodorant represented by Formula (1) or Formula (2), is provided. The polyurethane foam prepared by using said polyurethane composition exhibits extremely low odor intensity and superior performance properties, e.g. foaming degree and mechanical strength. A method for preparing a polyurethane foam with reduced odor is also provided.

1 . A polyurethane composition for preparing a polyurethane foam, comprising
 (A) at least one isocyanate compound comprising at least two isocyanate groups;   (B) at least one polyol compound; and   (C) an amine-based catalyst system, comprising   (C1) at least one amine-based catalyst selected from the group consisting of aliphatic diamine, aliphatic triamine, cycloaliphatic monoamine, cycloaliphatic diamine, cycloaliphatic triamine, araliphatic monoamine, araliphatic diamine, araliphatic triamine, aromatic monoamine, aromatic diamine, aromatic triamines, heterocyclic monoamine, heterocyclic diamine, heterocyclic triamine, and any combinations thereof; and   (C2) at least one deodorant represented by Formula (1) or Formula (2)   
       
         
           
           
               
               
           
         
       
       wherein R 1  is hydrogen or methyl, R 2  is selected from the group consisting of C 1 -C 12  alkyl, hydroxy-substituted C 1 -C 12  alkyl, and (meth)acryloxy(C 1 -C 12  alkylene)-O—(C 1 -C 12 ) alkyl, and R 3  is selected from the group consisting of divalent C 2 -C 12  alkylene, trivalent C 3 -C 12  alkylene and tetravalent C 4 -C 12  alkylene, n is an integer of 2 to 4. 
     
     
         2 . The polyurethane composition according to  claim 1 , wherein R 1  is hydrogen, R 2  is selected from the group consisting of C 1 -C 12  alkyl, hydroxy-substituted C 1 -C 12  alkyl and acryloxy (C 1 -C 12  alkylene)-O—(C 1 -C 12 ) alkyl, and R 3  is selected from the group consisting of divalent C 2 -C 6  alkylene, trivalent C 3 -C 6  alkylene and tetravalent C 4 -C 6  alkylene. 
     
     
         3 . The polyurethane composition according to  claim 1 , wherein the deodorant is selected from the group consisting of ethyl acrylate, propyl acrylate, butyl acrylate, pentyl acrylate, hexyl acrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl acrylate, 4-hydroxybutyl acrylate, 5-hydroxypentyl acrylate, 6-hydroxyhexyl acrylate, glycidyl diacrylate, ethylene diol diacrylate, propylene diol diacrylate, butylene diol diarcylate, hexane diol diacrylate, glycerol triacrylate, erythritol tetra(acrylate), pentaerythritol tetra(acrylate) and any combinations thereof. 
     
     
         4 . The polyurethane composition according to  claim 1 , wherein the amine-based catalyst is selected from the group consisting of ethylene diamine, propylene diamine, butylene diamine, pentylene diamine, neopentylenediamine, hexylene diamine, heptylene diamine, neoheptylene diamine, N,N-dimethylcyclohexylamine, bis(2-dimethylaminoethyl) ether, methyltriethylenediamine, dimethylaminopropylamine, bis(N,N-dimethyl-3-amino-propyl)amine, bis(2-dimethylaminoethyl)ether, 1,1′-((3-(di-methylamino)propyl)azanediyl) bis(propan-2-ol), 2,4,6-tridimethylamino-methyl)phenol, N,N,N′, N′-tetra-methyl-ethylene diamine, N,N,N′,N′-tetramethyl-propylenediamine, N,N,N′,N′-tetramethyl-butylenediamine, N,N,N′,N′-tetramethyl-pentylenediamine, N,N,N′,N′-tetramethyl-hexylene diamine, N,N-dimethyl benzylamine, triethylenediamine, pentamethyldiethylenetriamine, diethylenetriamine, N-methylmorpholine, N-ethyl morpholine, 2-methylpropanediamine, N,N′-diethylpiperazine, N,N′-dimethyl piperazine, pyridine, N,N′-dimethyl pyridine, quinoline, N,N′,N″-tris(dimethyl amino-propyl)sym-hexahydro triazine, and any combinations thereof. 
     
     
         5 . The polyurethane composition according to  claim 1 , wherein the amine-based catalyst is represented by Formula (3) 
       
         
           
           
               
               
           
         
       
       wherein m is an integer of 2 to 12, each of R 3  to R 6  is independently selected from the group consisting of H, C 1 -C 12  alkyl, hydroxy-substituted C 1 -C 12  alkyl, amino-substituted C 1 -C 12  alkyl and amine-substituted C 1 -C 12  alkyl. 
     
     
         6 . The polyurethane composition according to  claim 1 , wherein the weight ratio between the deodorant and the amine-based catalyst is from 0.5:100 to 15:100. 
     
     
         7 . The polyurethane composition according to  claim 1 , wherein
 the isocyanate compound is selected from the group consisting of:   a) C 2 -C 12  aliphatic isocyanate compound comprising at least two isocyanate groups, C 6 -C 15  cycloaliphatic isocyanate compound comprising at least two isocyanate groups, C 6 -C 15  aromatic isocyanate compound comprising at least two isocyanate groups, C 7 -C 15  araliphatic isocyanate compound comprising at least two isocyanate groups, or a combination thereof; and   b) an isocyanate prepolymer prepared by reacting one or more isocyanate compound of a) with one or more isocyanate-reactive component selected from the group consisting of C 2 -C 16  aliphatic polyhydric alcohol comprising at least two hydroxy groups, C 5 -C 16  cycloaliphatic polyhydric alcohol comprising at least two hydroxy groups, C 6 -C 16  aromatic polyhydric alcohol comprising at least two hydroxy groups, C 7 -C 15  araliphatic polyhydric alcohol comprising at least two hydroxy groups, polyester polyol having a molecular weight from 500 to 5,000, polycarbonate polyol having a molecular weight from 200 to 5,000, polyether polyol having a molecular weight from 200 to 5,000, or any combinations thereof, with the proviso that the isocyanate prepolymer comprises at least two free isocyanate groups; and   the polyol compound is selected from the group consisting of C 2 -C 16  aliphatic polyhydric alcohol comprising at least two hydroxyl groups, C 6 -C 16  cycloaliphatic polyhydric alcohol comprising at least two hydroxyl groups, C 6 -C 16  aromatic polyhydric alcohol comprising at least two hydroxyl groups, C 7 -C 15  araliphatic polyhydric alcohol comprising at least two hydroxyl groups, polyester polyol having a molecular weight from 500 to 12,000, polycarbonate polyol having a molecular weight from 200 to 8,000, polyether polyol having a molecular weight from 200 to 8,000, core-shell polymer polyol having a core phase and a shell phase based on polyol, or any combinations thereof.   
     
     
         8 . The polyurethane composition according to  claim 1 , further comprising at least one additive selected from the group consisting of surfactant, chain extender, crosslinker, antioxidant, blowing agent, frothing agent, foam stabilizer, defoamer, tackifier, plasticizer, rheology modifier, UV-absorbent, light-stabilizer, co-catalyst, filler, colorant, pigment, water scavenger, solvent, diluent, flame retardant, slippery-resistance agent, antistatic agent, preservative, biocide and any combinations thereof. 
     
     
         9 . A polyurethane foam article, prepared by using the polyurethane composition according to  claim 1 . 
     
     
         10 . A method of producing a polyurethane foam, comprising the steps of:
 (i) combining at least one amine-based catalyst with at least one deodorant to form an amine-based catalyst system;   (ii) reacting at least one isocyanate compound comprising at least two isocyanate groups with at least one polyol compound in the presence of the amine-based catalyst system to produce the polyurethane foam;   wherein the amine-based catalyst is selected from the group consisting of aliphatic diamine, aliphatic triamine, cycloaliphatic monoamine, cycloaliphatic diamine, cycloaliphatic triamine, araliphatic monoamine, araliphatic diamine, araliphatic triamine, aromatic monoamine, aromatic diamine, aromatic triamines, heterocyclic monoamine, heterocyclic diamine, heterocyclic triamine, and any combinations thereof; and   the deodorant has a molecular structure represented by Formula (1) or Formula (2)   
       
         
           
           
               
               
           
         
       
       wherein R 1  is hydrogen or methyl, R 2  is selected from the group consisting of ethyl acrylate, propyl acrylate, butyl acrylate, pentyl acrylate, hexyl acrylate, C 1 -C 12  alkyl, hydroxy-substituted C 1 -C 12  alkyl, and (meth)acryloxy(C 1 -C 12 alkylene)-O—(C 1 -C 12 ) alkyl, and R 3  is selected from the group consisting of divalent C 2 -C 12  alkylene, trivalent C 3 -C 12  alkylene and tetravalent C 4 -C 12  alkylene, n is an integer of 2 to 4.